7 Maintenance and Repair

7.1 Chapter-related safety instructions

WARNING
Hazard due to involuntary movement!
Severe injury by starting bucket elevator belt.
Work may only be performed by maintenance personnel.
Empty the bucket elevator before maintenance work.
Switch off the bucket elevator and secure it against unexpected
starting.
Before beginning work, secure the ascending and descending strand
with a mechanical winch or chain hoist. The bucket elevator belt cannot
begin to move.
Do not work on the bucket elevator head and bucket elevator boot
simultaneously, be-cause tools can fall.
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Maintenance and Repair
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7.2 Inspection list
Inspection list
Belt bucket elevator
Interval
Component
Check
Comment
Entire machine
Annually
Steel structure
In order to avoid long-term damage, check for:
signs of corrosion
deformation of subassemblies
defective weld seams
Control devices
Quarterly

Speed monitor
In order to ensure proper function-ing, check the following:
the fastening of the electrical components
the fastening of the electrical connections
the cables for damage
If a component does not function properly, a fault message is displayed.
Fill level indicator
Off-track switch
Thermal switching device
Drive bracket
2,000 h
Motor
In order to ensure proper function-ing, check the following:
the anti-friction bearings for unusual noise during operation
the fastening of the electrical connections
the cables for damage
the cooling fins and air inlet openings for dirt
Observe the manufacturer's operating instructions.
Fluid coupling
the fluid coupling for tightness
the coupling set for wear and tear (max. 2/3 of the thickness)
Gear unit
the gear unit for tightness
compliance with the intervals of oil changing
Auxiliary drive unit
the geared motor for tightness
the overrunning clutch for func-tioning
Flexible coupling
the coupling set for wear and tear (max. 2/3 of the thickness)
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Inspection list
Belt bucket elevator
Interval
Component
Check
Comment
Bucket elevator head
2,000 h
Drive pulley
In order to ensure proper function-ing, check the following:
for slip-free drive of the convey-or belt
the drive pulley for caking
the surface for wear and tear
the crowning (at least 1 mm)
Pedestal bearing
for unusual noise during opera-tion
compliance with the relubrica-tion intervals
the screw and bolt connections for interference fit
Discharge plate
the discharge plate for wear and tear
the distance to the buckets (min. 10 mm)
The procedure is described in the "Bucket elevator head maintenance"
paragraph
Bucket elevator boot
4,000 h
Bucket elevator belt
In order to ensure proper function-ing, check the following:
the belt edges for damage
the belt surface for damage
the running of the belt
The procedure is described in the "Bucket elevator boot maintenance"
paragraph
Belt clamping con-nection

 the tightening torque of the nuts

Enter the check in the mainte-nance record.
The procedure is described in the "Bucket elevator belt mainte-nance"
paragraph.
Bucket
the bucket mounting
Enter the check in the mainte-nance record.
Replace defective buckets.
The procedure is described in the "Bucket elevator belt mainte-nance"
paragraph.
Enter inspection results under Comments.
Inspection performed on:___________by:________________________________
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7.3 Maintenance instructions
7.3.1 Cleaning of the bucket elevator
Maintenance also includes a regular cleaning according to the operating
conditions. The in-structions of the respective manufacturer for the
drive bracket included in the annexe must be observed. Cleaning of the
bucket elevator is restricted to the bucket elevator boot. The mate-rial
cakings must be removed regularly. At the latest when the buckets
brush material cakings, the bucket elevator boot must be cleaned.
NOTICE
Heavy material caking in the bucket elevator boot, or bucket elevator
boot overfilled
Buckets can be dislodged from the traction element.
Observe the signal of the fill level indicator.
Remove the material caking.
If the filling level indicator switches off the bucket elevator, the bucket
elevator boot is to be emptied manually. Only after that the bucket
elevator may be restarted.
How to clean the bucket elevator boot.
1. Switch off the material feed and perform two operating cycles of the
bucket elevator until all buckets are empty.
2. Turn the bucket elevator off and secure it against re-starting.

3. Secure the traction element against start-up in both directions of

running in case the bucket elevator boot must be entered for cleaning.
4. CAUTION The cleaning hatches may slam if they are not secured with
both flat bars. Large cleaning hatches must be opened and secured by
two persons.
5. Remove the material and the caking.
6. Close the cleaning hatches and secure them.
7. Remove the auxiliary means that you used for securing the traction
element against start-up.
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7.3.2 Maintenance of bucket elevator head
Required maintenance work at bucket elevator head:
Relubrication of pedestal bearings
Adjustment of discharge plate
Removing of deposits
Check of drive pulley crowning
Maintenance of drive components according to manufacturer's
instructions in the annexe
Visual check of the off-track switch for mechanical damage and
defective electrical con-nections
Adjustment of discharge plate
Fig. 37: "Discharge plate (16666)"
1
Bucket
2
Discharge plate
3
Fastening
1. Compare the distance between discharge plate and bucket edge with
the actual dimen-sion indicated in the assembly report.
2. Readjust the discharge plate in case of excessive fallback of spillage.

The minimum distance is to be checked during a complete rotation of

the buckets. In case of strong wear and tear, the discharge plate is to
be replaced whenever necessary.
3. Loosen the fastening bolts and push the discharge plate towards the
bucket edge until the indicated actual dimension is achieved.
4. Retighten the screw and bolt connections.
5. Remove the deposits from the discharge plate area.
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7.3.3 Maintenance of the bucket elevator boot
Required maintenance work at bucket elevator boot:
Checking the quantity of lubricant of the tension bearings at the sight
glass
Checking wear and tear of the membrane of the fill level indicator
Checking free movability of the parallel take-up station
Visual check of the off-track switches for mechanical damage and
defective electrical connections
Visual check of the speed monitor for mechanical damage and
defective electrical con-nections
Checking the crowning of the take-up pulley
Belt tracking correction
The belt must run centrally on the drive pulley and the take-up pulley.
During one rotation, the belt may move up to 30 mm to the right or to
the left. As soon as the belt position monitoring system has been
activated, the take-up pulley must be re-aligned. In the area of the belt
bucket elevator, the belt always moves to the side where the belt
tension is reduced. The necessary requirements for the belt tracking
correction are a precisely aligned drive pulley and a minimal crowning
of 1 mm at the drive pulley and the take-up pulley.
Fig. 38: "How to align the take-up pulley (16667)"
1
Take-up spindle
2
Hexagon nut
3
Parallel take-up device

4
Take-up pulley
5
Belt
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1. Adjust the position of the take-up pulley with the help of both takeup spindles.
2. Adjust the lever arms so that they are in a horizontal position.
3. Loosen both hexagon nuts under the counterweight for adjusting the
counterweight.
4. Loosen the locknut above the counterweight.
5. Adjust the take-up spindle approx. 5 mm upwards with the help of
the hexagon nut.
Adjust the take-up spindles step by step. Then observe the running of
the belt for several rotations as the effect of the correction only
appears after some time.
6. Fasten the counterweight to the take-up spindle by means of
hexagon nuts.
7. Perform a test run and observe the running of the belt.
If the take-up distance of the parallel take-up station is spent, the
counterweight must be lifted by the take-up spindles. As a result, the
lever arms must assume a horizontal position. Both sides must be
regularly adjusted.
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7.3.4 Maintenance of the bucket elevator belt
NOTICE
Hazard due to defective belt clamping connection or damage to the
bucket elevator belt!
The belt clamping connection could become loose and the bucket
elevator belt could fall.
Before casting the belt clamping connection, request a supervisor
from the supplier.

 The belt clamping connection must be installed and inspected in

accordance with the specifications in the operating instructions.
Enter the inspections in the test records.
The belt is to be subjected to a visual check every 6 months in order to
avoid it from falling. Pay attention to the following:
Damage to the belt edges
Cracks in the belt surface
Exposed wire ropes
Check the belt clamping connection
The clamping force at the belt ends decreases with the operating time.
That's why the tight-ening torque of the screws of the belt clamping
connection is to be checked in specified con-trol intervals. See
maintenance record in chapter 9.1 "Applicable documents", page 85
Fig. 39: "Check the belt clamping connection (16668)"
1. Remove the upper hexagon nuts.
2. Tighten the lower hexagon nuts with 500 Nm starting in the centre of
the belt clamping connection.
All hexagon nuts must be tightened with the torque of 500 Nm.
3. Mount the locknuts and tighten them with 500 Nm.
4. Enter the date of the check in the maintenance record.
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Check of bucket mounting
The clamping force at the belt ends decreases with the operating time.
Loosened screw and bolt connections are to be tightened. Segments
that have been displaced are to be aligned and fixed. It should not be
possible to move the segments by hand. After a certain operating time,
the belt may bulge above and below the segments. Due to this, the
indentation depth of the segments may increase by some millimetres
compared with the belt contact surface. The mounting of the buckets is
to be checked in specified control intervals. See maintenance record in
chapter 9.1 "Applicable documents", page 85
1. Check the bucket mounting for interference fit and displaced
segments.
2. If bucket mountings are loosened or segments are displaced, remove
the locknuts.
3. Align the segments and tighten the special nuts.

4. Secure the special nuts with the locknuts.

5. Enter the check in the maintenance record.
Article number of the segment
314117
314119
Indentation depth
approx. 4 mm
approx. 6 mm
Tightening torque
70 Nm
90 Nm
Max. tightening torque
120 Nm
140 Nm
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7.4 Instructions for repairs
7.4.1 Replacement of segmented lagging
The segmented lagging at the drive pulley is divided into single
segments. The segments can be replaced without dismounting the
complete bucket elevator belt. The segments may be taken out through
the opened lateral assembly openings.
The weight of a segment with respect to the bucket elevator size can be
found in the follow-ing table.
Bucket elevator size
160
200
250
315
400
500
630

Weight (kg)
12
13
18
19
21
27
37
Bucket elevator size
800
1,000
1,250
1,400
1,600
1,800
2,000
Weight (kg)
60
86
1100
158
200
223
250
1. Remove the covers of the lateral assembly openings.
2. Push a stable support plate underneath the drive pulley through the
assembly openings.
3. Loosen the nuts of the segment fastening.
4. WARNING Risk of crushing from a falling segment!Put the segment
on the sup-port plate and pull it sideways from the bucket elevator
head.
5. Push the new segment into the bucket elevator boot and screw it to
the drive pulley.

6. WARNING Do not reach into the bucket elevator!Rotate the drive

pulley so far that you may proceed with the replacement of the next
segment.
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7.4.2 How to replace the tension bearings
The tension bearings have to be relieved before being replaced. For this
purpose, lift the take-up pulley in the bucket elevator boot and fasten it
to the boot casing. The inspection hatches of the tension bearings are
opened and the take-up spindles screwed off. The slide ring seal must
be replaced every time it is dismounted.
Fig. 40: "Replacement of tension bearing (16669)"
1
Ring
2
Slide ring seal
3
Cam
4
Bearing housing
5
Bearing end cover
6
Activator plate
7
Retaining ring
8
Anti-friction bearings
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How to dismount the tension bearing

1. Fasten the take-up pulley to the lifting lugs of the bucket elevator
boot by using lifting equipment and lift it.
2. On both sides, remove the flaps arranged in front of the tension
bearings.
3. Loosen the take-up spindles and unscrew them from the tension
bearings.
4. CAUTION Risks of burns due to hot oilDrain off the oil as described in
the chapter "Change of lubricant at tension bearings".
The tension bearing can now be dismounted.
5. Remove the bearing end cover and the activator plate.
6. Fasten a detaching device to the cam and pull the bearing housing
from the take-up axle.
7. Remove the retaining ring and press the anti-friction bearing out of
the bearing housing.
8. Pull the slide ring seal from the take-up axle. NOTICE The slide ring
seal must be replaced every time it is dismounted.
9. Loosen the stud bolt and pull the ring from the take-up axle. The
rotary shaft seal must not be damaged.
10. Mount the components in reverse order.
The proximity switch may not overhang more than 13 mm to avoid
being damaged by the activator plate.
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7.5 General lubrication instructions
Only if the appropriate lubricant is applied and the lubrication intervals
are kept, can the lubri-cant meet the requirements (good lubricating
film, reduction of wear and tear, corrosion pro-tection, noise
absorption, heat emission, sealing, etc.). This contributes considerably
to achieving a good performance, reducing failures and ensuring an
adequate service life of the machine.
Synthetic lubricants must not be mixed with mineral ones!
In general, fixed intervals for changing the lubricant and re-lubrication
cannot be specified as they depend on different factors. The respective
operating conditions such as ambient condi-tions, operating time and
load are decisive.
Table of lubricants
The lubricants required for the machine are listed in the table of
lubricants. Further infor-mation on lubrication and lubrication points is

indicated in the operation instructions of the respective manufacturers.

The intervals for lubrication and lubrication changes are essentially
dependent on the thermal load. The higher the lubricant temperature,
the shorter the intervals for changing the lubricant.
Only use the lubricants approved by the manufacturers to avoid
damage to the machine parts.
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7.5.1 Change of lubricant at tension bearing
The tension bearing is filled with an axle gear oil SAE 90, type Shell
Spirax MB 90. With the indicated quantity of lubricant, the sight glass is
half covered. The oil has to be changed ei-ther after 15,000 operating
hours or after 3 years.
Only carry out the oil change at operating temperature. If the oil is too
cold, discharge be-comes more difficult.
Fig. 41: "Change of lubricant at tension bearing (16672)"
1
Oil filler plug
2
Sight glass
3
Oil tank
4
Oil drain plug
5
Filler neck
Change the oil of the tension bearing
1. Place a container under the oil drain plug.
2. First remove the oil drain plug and the oil filler plug, then drain off
the oil completely.
3. Mount the oil drain plug.
4. Fill in fresh axle gear oil of class SAE 90 until the sight glass is half
covered.
5. Mount the oil filler plug.
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Maintenance and Repair

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7.5.2 Lubricant specification
No.
Component
Type
Fill quantity
Interval
1
Gear unit*
see rating plate
see operating instructions
2
Geared motor
CLP CC VG 220
7.7 l
First change after 2 (a), further changes after < 2 (a)
3
Fluid coupling*
HLP VG 32
13.0 l
15,000 (h)
4
2 x pedestal bearing (drive pulley)
KP2N-20
3800 g
15,000 (h)
5
2 x tension bearing (take-up pulley)
SAE 90
0.7 l
15,000 (h)

Comment:
No.:
Row number (for reference)
Component:
Designation of the components (components marked with * are
supplied without oil)
Type:
Designation of the lubricant in accordance with DIN (ISO)
Fill quantity:
Fill quantity (litre for oil, kilogram for grease) per lubrication point
The individual fill quantities are indicated on the rating plate.
Interval:
Intervals for changing the lubricant
after working hours (h)
latest change due to ageing after years (a)